Systems and methods for processing packaged goods in the nature of cigarettes

ABSTRACT

Systems and methods for processing tobacco-oriented goods are disclosed. One embodiment of a method includes receiving a pick-up signal from a pick-up sensor. The pick-up signal is indicative of the picking up of a tobacco product unit that has been pre-sorted based on inclusion in an associated order. Also received is a put-down signal from a put-down sensor. The put-down signal is indicative of the fact that the tobacco product unit has been put down. A determination is made, based on a system parameter, whether the pick-up signal is properly associated with the put-down signal.

BACKGROUND

The present application is based on and claims the benefit of U.S.provisional patent application Ser. No. 60/795,931, filed Apr. 27, 2006,and is also based on and claims the benefit of U.S. provisional patentapplication Ser. No. 60/847,033, filed Sep. 25, 2006, the content ofboth provisional applications being hereby incorporated by reference inits entirety.

Currently, there are many different types of materials handling systems.Typically, such a system will include equipment configured to move itemsbetween required locations on an automated and/or manually-initiatedbasis. Depending on the type of items being handled, some systems mayincorporate the functionality of specialized equipment, such asequipment for weighing or performing some other measurement functionwithin the materials handling system.

Some materials handling systems are designed specifically for processingpackaged tobacco products, such as cartons of cigarettes. Currently,there are many disadvantages associated with such systems. For example,in terms of operator function, most systems require frequent movement ofthe operator to the product rather than bringing the product to theoperator. Further, while some current systems support the passing ofpackages of tobacco products through a stamping machine, there areusually significant limitations on the flexibility of the stampingprocess. Still further, current systems commonly support the sorting ofone package to a single order at a time.

The discussion above is merely provided for general backgroundinformation and is not intended for use as an aid in determining thescope of the claimed subject matter. Also, the claimed subject matter isnot limited to implementations that solve any or all disadvantages notedin this background section.

SUMMARY

Systems and methods for processing tobacco-oriented goods are disclosed.One embodiment of a method includes receiving a pick-up signal from apick-up sensor. The pick-up signal is indicative of the picking up of atobacco product unit that has been pre-sorted based on inclusion in anassociated order. Also received is a put-down signal from a put-downsensor. The put-down signal is indicative of the fact that the tobaccoproduct unit has been put down. A determination is made, based on asystem parameter, whether the pick-up signal is properly associated withthe put-down signal.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is schematic diagram of a materials handling system forprocessing tobacco-oriented goods.

FIG. 2 is a flow chart diagram demonstrating process steps that, in oneembodiment, are executed within the materials handling system.

FIG. 3 is a schematic diagram of a computing device with materialshandling system software operatively installed thereon.

FIG. 4 is a perspective view of a portion of the materials handlingsystem.

FIG. 5 is a perspective view of a portion of the materials handlingsystem.

FIG. 6 is a simplified schematic representation of a specializedconveyor system.

FIG. 7 is a perspective view of a portion of the materials handlingsystem.

FIG. 8 is a perspective view of a portion of the materials handlingsystem.

FIG. 9 is a flow chart diagram demonstrating steps associated with apacking process.

FIG. 10 is a perspective view of a portion of the materials handlingsystem.

DETAILED DESCRIPTION

FIG. 1 is a schematic diagram of a materials handling system 100 forprocessing packaged tobacco products, such as, but not necessarilylimited to, cartons of cigarettes. FIG. 2 is a flow chart diagramdemonstrating processing steps that occur within system 102. FIG. 3 is aschematic diagram of a computing device 302 having materials handlingsystem software 304 operatively installed thereon. Software 304 isillustratively configured to facilitate the management of variousfunctions associated with operation of materials handling system 100,many of which will be described in detail below. The components andoperation of system 100 will be described in relation to the relatedprocess of FIG. 2, as well as in relation to related components ofsoftware 304.

In accordance with block 202 in FIG. 2, a first step in the overallmaterials handling process is product picking. Generally speaking, inthe context of FIG. 1, the picking process involves removing cartons ofcigarettes from picking stations 102 and placing them onto a conveyor104 that moves the cartons from right to left (relative to theorientation of FIG. 1).

In one embodiment, software component 305 is configured to interfacewith system 100 so as to support management of the picking process. Theprecise details of configuration will vary depending upon the details ofa given picking implementation. Without departing from the scope of thepresent invention, the picking process can be entirely automated,semi-automated or entirely manually accomplished. In one example of apurely manual implementation, a human selects cartons from one or morepicking stations 102 based on instructions reflected in a paper-basedlisting, for example, a paper-based listing of what products should bepicked and in what sequence.

In a typical semi-automated picking system, a human selects cartons fromone or more of the picking stations 102 based on an electronicallysupported system that presents automated cues (e.g., visual or audiblecues). In one embodiment, a mechanism is employed to verify that humanhas properly responded to the cues. For example, the system may requirethe human to provide feedback (e.g., pushing a button, speak a commandinto a microphone, etc.) to verify compliance with a particular cue,which illustratively triggers initiation of the next cue. An alarm orsome other response is illustratively provided if feedback from thehuman picker is inconsistent with expectations based on the currentlyactive cue.

In a more specific example of a semi-automated picking system, an LED isilluminated to identify a product type (e.g., the identity, SKU and/orlocation) as the next candidate for picking. The same or a different LEDmechanism also indicates the quantity to be picked. Once picked, the LEDmechanism or mechanisms are turned off in a manner that indicatescompliance with the picking instruction. This may occur in any of avariety of different ways such as, but not limited to, depression of abutton by the human picker. Alternatively, the indicator(s) may beautomatically extinguished when determined by a sensor (e.g., anelectronic eye, a laser sensor, etc.) that the current pickinginstruction is likely to have been fulfilled.

In another example, an audibly directed picking system is implementedwherein audible commands are transmitted to an operator-worn headset tonotify a human operator of the next pick location, quantity,description, check digit for verification purposes, and/or some otherform of instruction. In one embodiment, the operator speaks into amicrophone to notify the system, via speech recognition, of exceptionsand/or pick verification. It should be noted that hybrid systems arealso within the scope of the present invention, such as a system whereinvisual aids are utilized to provide picking locations and audible cuesare utilized to indicate the applicable quantity, exceptions,completions, and/or other picking-related information.

Those skilled in the art will appreciate that the pickingimplementations provided in the previous paragraphs are simply examplesof many alternatives within the scope of the present invention. Fullyautomated alternatives, such as where machines handle automatically theprocess of moving cartons to conveyer 104, are also within the scope ofthe present invention. The present invention is not limited to any oneparticular means for implementing the picking process.

In one embodiment, not by limitation, picking stations 102 includeshelves containing cigarettes in bulk quantities organized by type. Forexample, cartons of a particular type of Marlboro cigarettes are groupedtogether in a first location while cartons of a particular type of Camelcigarettes are grouped together in a different location (though a giventype might be stocked in more than one location).

In one embodiment, logic is applied to selectively organize anddistribute products across and/or within the picking stations 104. Forexample, certain types of product may be assigned certain locationsbased on an objective criteria such as, but not necessarily limited to,anticipated quantities needed. In this case, a type likely to be neededrelatively frequently might be assigned a location that is easier toaccess (e.g., by a human) than a location assigned to a type that islikely to be less frequently needed. Or, a type of product likely to beneeded in large quantities might be assigned a location that is easierto access than a location assigned to a type that is more likely to beneeded in small quantities. One area might be reserved for picking largequantities (e.g., cases of cartons) of a product while another areamight be reserved for picking small quantities (e.g., individualcartons) of the same product. Those skilled in the art will appreciatethat it is within the scope of the present invention to organizeproducts across and/or within picking stations 102 based on any basis.The basis may include, but is not limited to, the goal of maximizingefficiency (e.g., reducing the amount of movement required for a humanparticipating in the picking process).

Picking instructions are illustratively generated within software system304 (e.g., by support components 305) and issued into materials handlingsystem 100 as appropriate depending upon the nature of the implementedpicking system. In one embodiment, the picking instructions areorganized around the concept of an order. For example, all components ofa first order are picked (e.g., placed on conveyer 104). Then, then allthe components of a second order are picked. This process continuesuntil all orders have been picked. Some efficiency considerations may beworked in to the order-based picking process. For example, certainorders may be given higher priority than others for a variety ofdifferent reasons (e.g., truck scheduling, etc.). Or, the componentswithin an order may be organized to minimize how much a human pickermust move around while picking the order. However, it is typically truethat all components of a first order must be picked before moving on toa second order. To compromise this mandate will typically meancompromising the accuracy of order management downstream in the system.

In one embodiment, as is shown in FIG. 3, materials handling softwaresystem 304 includes a batch handling component 306. Component 306 isillustratively a software tool that enables a user to influence thequantity and type of products to be picked, as well as the order inwhich picking occurs. How this influence is translated to the pickingprocess is dependent upon the nature of the picking system. For example,in one embodiment, in a purely manual system, software component 306 isconfigured to assist in the generation of a list or lists from which oneor more human pickers work. In another embodiment, in a semi-automatedsystem, software component 306 is configured to influence what cues areprovided to one or more human pickers. In yet another embodiment, in anautomated system, software component 306 is configured to influence theoperation of the machines responsible for the picking process. Thoseskilled in the art will appreciate that the precise functionality ofsoftware component 306 is at least partially dependent upon the natureof the applicable picking implementation.

In accordance with one embodiment, picking instructions generated bycomponent 306 are organized around the concept of a batch. Generallyspeaking, a single batch may contain components from different orders.Typically, components of a first batch are picked followed by thepicking of components of a second batch, and so on and so forth untilall batches have been picked. The assumption is that orders can be mixedbecause other mechanisms are utilized downstream in the system in orderto organize on an order-specific basis. The components of a batch aretypically picked from a single inventory of product (e.g., distributedacross picking stations 102). A human participant in a batch-basedpicking process illustratively may not be aware (e.g., may receive noindication) of what specific order he or she is in the process ofpicking.

In one embodiment, software component 306 is configured to receiveindications of orders and generate corresponding batch-based pickingorders in accordance with one or more user-selected and/or defaultorganizing principles. This illustratively, but not necessarily, meanscombining components of different orders into the same batch. This isnot to say that batch-based picking instructions must originate withinmaterials handling system software 306. Those skilled in the art willappreciate that batch-based picking instructions can be generated by anexternal system and transmitted to software 304 (e.g., to component 306)for processing within the applicable picking system (e.g., system 100).

As has been alluded to, the batch-based picking instructions can beorganized based on any of a variety of different user-selected and/ordefault parameters. For example, not by limitation, software component306 can be configured to create batches so as to optimize one or more ofthe following constraints in any combination: 1) desired ordercompletion cutoff time; 2) desired truck route or routs; 3) desiredcarton size or sizes in a batch; 4) target overall batch size; and/or 5)target work effort to complete the batch. In one embodiment, allavailable orders are merged into the batching process. In anotherembodiment; however, software 304 and/or system 100 are configured tosupport either or both batch-based and order-based picking.

FIG. 4 is a perspective view of a portion of system 100. The view showsthe two picking stations 102 that are located closest to a pair ofstamping machines 106. Stations 102 are shown as empty but would moretypically be stocked with products. Conveyer 104 is shown in FIG. 4.Picked cartons of tobacco products move down conveyer 104 towardstamping machines 106.

In one embodiment, items are picked in either case quantities (e.g., 30cartons per case) or individual cartons (based on picking instructions).Picked cartons are placed on conveyor 104 and, in one embodiment, areoriented such that the widest dimension of the carton is perpendicularto the direction of travel. The flaps of the carton are illustrativelyoriented so as to be conducive to properly entering stamping machines106. A second takeaway conveyer 108 is illustratively provided andoperates beneath conveyor 104. Case quantities are placed onto the lowerconveyor 108.

Thus, an instruction to pick a large quantity of a given product can bepicked by placing a case of the product on the lower conveyor and thenone or more individual cartons on the upper conveyor as necessary toround out the total number of cartons needed. In one embodiment, such apicking instruction requires the person picking to use their intuitionto determine when a case can be picked rather than individual cartons.In another embodiment; however, picking support components 305 areconfigured to automate such determinations and incorporate the option ofcase picking into the picking instructions. Depending on exactly how therest of system 100 is set up, assumptions based on the expectation ofone or more cases may or may not be made downstream from the pickingprocess. For example, if an instruction is made to pick a case, thendownstream processing may or may not require the case to turn up on thelower conveyor rather than an equivalent amount being pickedindividually and placed on the upper conveyor. Whether or not there willbe such a dependency is a detail that is likely to beimplementation-specific.

In accordance with block 204 in FIG. 2, a next step in the process is toroute picked products to stamping machines 106. At this point, it isprobably a good idea to emphasize that the present invention is notlimited to the particular configuration of system components shown inFIG. 1. Those skilled in the art will appreciate that a givenimplementation is likely to be highly customized to match the givenneeds of a particular owner or operator. With that in mind, it should bepointed out that the present invention is not limited to incorporatingtwo stamp machines 106. More or fewer stamping machines can beimplemented without departing from the scope of the present invention.However, solely for the purpose of describing various aspects of thepresent invention in detail, the illustrated case of two stampingmachines will be assumed.

In one embodiment, as products exit the picking area and approach thestamp machines, two pick conveyors feed the stamp machines 106. As isshown in FIG. 5, a lower conveyor handles bulk quantities. A case 116,which assumedly contains individual cartons, is shown on the lowerconveyor for illustratively purposes. In one embodiment, case quantitiesare diverted from the lower conveyor into a stamping workstation asdetermined to be appropriate based on applicable processing parameters.A component of software 304, namely, a location management component308, is illustratively configured to account for such parameters andtrigger mechanical functionality within system 100 as necessary toappropriately move items through the system.

When a case arrives at a stamping work station, a human operator (e.g.,an operator of the corresponding stamping machine 106) unloads the casesand manually places the individual cartons onto an induction conveyorassociated with the stamp machine. In one embodiment, instructionsand/or information related to this bulk unloading task are provided byway of interface 112. In one embodiment, when the task has beencompleted, an indication of completion is provided to locationmanagement component 308 by way of input mechanism 114. When aprocessing error occurs (e.g., a bulk item does not get unpacked, etc.),an exception is illustratively triggered within component 308 andcommunicates through operator interface 112. It should be noted that, itis also within the scope of the present invention to make unloading thebulk quantities into the stamp machine an automated process.

In one embodiment, in order to facilitate routing to an appropriatestamping machine 106, individual cartons on the upper conveyor aretransferred onto a specialized conveyor system. FIG. 6 is a simplifiedschematic representation of the specialized conveyor system, which isidentified in the Figure as conveyor 600. Conveyor 600 has a pluralityof partitions 606 (a representative few of which have been labeled) thatextend generally perpendicular to the surface 602 of the conveyor. Thespacing between partitions is illustratively slightly more than thenarrowest dimension of a carton positioned perpendicular to thedirection of conveyor travel.

In one embodiment, as cartons are transferred from the upper conveyor104 into specialized conveyor system 600 (e.g., similar to the twosample cartons 604 shown in FIG. 6), a reader reads an identifier fromeach carton. Those skilled in the art will appreciate that thisidentification process could involve application of any of a number ofdifferent identifying technologies including but not limited to an RFIDidentification system, a barcode identification system, a CCD deviceidentification system, or any other identification system. In oneembodiment, this information is fed into an item tracking component 310,which is part of software system 304. Component 310 illustrativelyassociated the carton's ID with its position in the partitioned conveyor600.

In one embodiment, item location management component 308 receives itemlocation information from item tracking component 310 and utilizes it asa basis for sorting cartons into appropriate stamping machines. Forexample, as cartons move on conveyor 600 proximate to the entry pointsof stamping machines 106, component 308 selectively energizes one ormore pushing devices to selectively push cartons into appropriatestamping machines. The determination as to the optimum path for a givencarton (i.e., which is the correct stamping machine) is illustrativelybased upon system parameters that are set by system default and/or on auser-selectable basis (e.g., set by an operator of software 304).

In one embodiment, software 304 is configured to support sorting cartonsthrough stamping machines based upon the taxing authority or authoritiesfor which each individual stamping machine is set up to support stampingfunctionality. It is specifically within the scope of the presentinvention for multiple taxing authorities to be picked in a singlebatch. For example, the components of a single picked batch may movethrough different stamp machines set up to support different taxingauthorities. This is particularly interesting in light of the fact that,as has been discussed, a given batch may contain components from morethan one order (e.g., multiple orders headed to different locations).

In another embodiment, software 304 is configured to support sortingcartons through stamping machines based upon optimization of the totalorder fulfillment cycle for a given batch, or for some other measurementstandard such as but not limited to a period of an entire shift. Thoseskilled in the art will appreciate that software 304 can be configuredto support sorting cartons through stamping machines based on manydifferent factors in addition to those specifically listed herein, towhich the scope of the present invention is not limited.

In one embodiment, cartons may be sorted among stamping machines basedupon an administrator- or operator-defined set of rules that are createdwithin software system 304. In one embodiment, if a carton is notdestined for any of the stamping machines for any reason, the softwareis configured to stop the partitioned conveyor, as well as all conveyorsupstream as required. Or, in one embodiment, the software is configuredto push the carton(s) into an exception handling area, for example. Inone embodiment, the handling of such exceptions is configurable basedupon an administrator- or operator-selectable option.

Those skilled in the art will appreciate that the display 112 and inputmechanism 114 (FIG. 5) associated each stamp machine 106 can beconfigured to support a variety of different functions. Software system304 includes stamp machine support components 312 for supporting suchfunctionality.

In one embodiment, as cartons are scanned (e.g., while being moved intoconveyor 600), components 312 are configured to indicate on display 112the quantity of cartons scanned compared against a total required foreach stamping machine and/or the tax jurisdiction(s) for which thestamping machine is configured. In one embodiment, components 312 areconfigured to enable an operator to input (e.g., through mechanism 114,through a touch screen implementation of display 112, etc.) informationor exceptions as cartons are stamped. For example, the operator is ableto enter commands or notifications to cause software 304 to initiate anappropriate response in unusual circumstances such as, but not limitedto, if there is damage to a carton, if a stamping machine becomesinoperable, or if other unusual situations arise during stamping.

In one embodiment, software components 312 are configured to provide,through display 112, instructions for operators who receive full casequantities (e.g., on the lower conveyor coming from the picking area) sothat they know how many cartons to remove from the case and route intothe stamping machine. For example, it is conceivable that the system maybe configured to enable less than all cartons (e.g., less than all 30cartons) in a bulk amount received to be indicated for processing.

In one aspect of the present invention, as cartons move through stampingmachines 106 and are stamped with their unique tax jurisdictional stampor stamps, an additional step is taken to support the subsequenttracking of each carton within system 100. In one embodiment, a firstidentifying mark is applied to each carton. The first identifying markillustratively does not deface the carton and, in one embodiment, isinvisible in that it is generally imperceptible to the human eye but canbe made visible (e.g., by placing under a black light), and/or isvisible to a scanner designed to “see” such marks. In addition oralternatively, a second identifying mark that does deface the carton(e.g., a bar code label) is applied (e.g., blown onto) to each carton.The application and tracking of labels is illustratively managed by oneor more of the sub-components of software system 304.

Various embodiments and components of the present invention involveapplying identifiers to product units and/or reading identifiersassociated with product units. Those skilled in the art will appreciatethat these identification processes could involve application of any ofa number of different identifying technologies including but not limitedto an RFID identification system, a barcode identification system, a CCDdevice identification system, or any other identification system. To theextent that the present description identifies specific technologies,the specific technologies are provided as but one example of animplementation within the scope of the present invention.

In accordance with block 206 in FIG. 2, a next step in the process is toroute cartons from stamp machines 106 to one or more sorting mechanisms140. In FIG. 1, each stamp machine 106 is associated with a separatesorting mechanism. Those skilled in the art will appreciate that this isnot the only configuration within the scope of the present invention.

For example, in one embodiment, multiple stamp machines 106 feed intothe same sorting mechanism 140. In another embodiment, one stampmachines feeds into multiple sorting mechanisms 140. In general, it iswithin the scope of the present invention to customize the configurationof system 100 (add, subtract and/or re-arrange the system components) asnecessary to fulfill applicable needs. It is also within the scope ofthe present invention that software system 304 is flexibly configured toeffectively support all such configurations.

In one embodiment, as is generally shown in FIG. 5, cartons aretransferred out of a stamp machine 106 and onto a conveyor that isconfigured to transport the cartons such that the longest dimensiontravels parallel to the direction of conveyor flow. However, it is alsowithin the scope of the present invention for cartons to be ejected froma stamping machine 106 directly into a sort mechanism 140. Whethercartons are directly or indirectly transferred into a sorting mechanismis dependent on a variety of implementation-specific details such asphysical space limitations and configurations at a particular site wherea system 100 is to be installed.

In one embodiment, a carton approaches a sorting mechanism 140 and isloaded into a specialized sorting conveyor system. In one embodiment,the specialized sorting conveyor system is configured the same orsimilar to conveyor 600 shown in FIG. 6. The conveyor has a plurality ofpartitions that extend generally perpendicular to the surface of theconveyor. The spacing between partitions is illustratively slightly morethan the narrowest dimension of a carton positioned perpendicular to thedirection of conveyor travel. Cartons feed into the specialized sortingconveyor system as was described in relation to FIG. 6.

FIG. 7 is a schematic illustration demonstrating movement of cartonsinto and through a sorting mechanism 140. At point 702, cartons aretransferred from a conveyor that moves cartons (moving parallel to thelongest dimension) to a partitioned conveyor the same or similar toconveyor 600 in FIG. 6 (e.g., wherein cartons are moved perpendicular tothe longest dimension). It should be noted that, referring to FIG. 7,the sorting mechanism located more toward the top of the Figure isequipped with its own specialized sort conveyor for moving the otherstream of cartons through the other sorting mechanism 140. Also, itshould be emphasized that it is also within the scope of the presentinvention to transfer cartons directly from a stamping machine 106 intoone of the partitioned sorting conveyors associated with the sortingmechanism 140.

In one embodiment, as cartons are transferred into the specializedsorting conveyors, a devices reads an identifier associated with eachcarton (e.g., a barcode scanner reads the manufacturer-applied barcodefrom each carton) (though this additional item tracking step may beoptional for a given implementation). Those skilled in the art willappreciate that this identification process could involve application ofany of a number of different identifying technologies including but notlimited to an RFID identification system, a barcode identificationsystem, a CCD device identification system, or any other identificationsystem. In one embodiment, this information is fed into item trackingcomponent 310, which is part of software system 304. Component 310illustratively associated the carton's ID with its position in thepartitioned conveyor.

In one embodiment, item location management component 308 receives itemlocation information from item tracking component 310 and utilizes it asa basis for selectively ejecting cartons (e.g., by selectivelyenergizing one or more pushing mechanisms) onto a takeaway conveyer.FIG. 7 shows ejected cartons moving (longest dimension parallel to thedirection of motion) along the takeaway conveyor toward a plurality ofboxes 704. The determination as to the optimum path for a given carton(i.e., which boxes 704 to move toward) is illustratively based uponsystem parameters that are set by system default and/or on auser-selectable basis (e.g., set by an operator of software 304).

Thus, as a carton moves into the eject window of a conveyor, a pushingmechanism ejects the carton onto the takeaway conveyor. In oneembodiment, the ejection determination is based at least in part on theorder to which the carton is assigned (e.g., the assignment of ordersbeing tracked by a component of software 304).

Those skilled in the art will appreciate that it is within the scope ofthe present invention to adjacently line up multiple takeaway conveyors.In one embodiment, each takeaway conveyor has its own specializedsorting conveyor system (e.g., similar to conveyor 600), the hardwareand software being configured to appropriately route a given carton tothe takeaway conveyor associated with the carton's final destinationwhile bypassing the other takeaway conveyors. In another embodiment, asingle specialized sorting conveyor feeds multiple takeaway conveyors(e.g., the carton moves along all the takeaway conveyors until ejectionfrom the specialized sorting conveyor is appropriate based on systemparameters).

Regardless of the configuration of sorting mechanisms 140, andregardless of whether there is more than one, the purpose of themechanism or mechanisms is illustratively to sort the cartons based onparameters set within software 304. The parameters are indicative of oneor more bases for organization such as but not limited to order-orientedorganization. Those skilled in the art will appreciate that software 304can be configured to support sorting cartons through sorting mechanisms140 based on many different factors in addition to order-orientedorganization, to which the scope of the present invention is notlimited. In one embodiment, cartons may be sorted based upon anadministrator- or operator-defined set of rules that are created withinsoftware system 304. Finally, it is worth specifically pointing out thatit is within the scope of the present invention for cartons to be pickedon a batch-oriented basis (e.g., with multiple orders distributed acrossa single batch) and then, after the stamping process, sorted on anorder-specific or some other basis.

In accordance with step 208, a next step in the process is to collectthe cartons from the end of the sorting mechanism takeaway conveyers andpack them into boxes 704. When cartons arrive at the end of the sortmechanism takeaway conveyor, they are sorted to the extent that anoperator can simply pick them up directly from the end of the conveyorand place them into a corresponding box 704. FIG. 8 is a schematicillustration showing an operator 802 standing in front of boxes 704.

Cartons that are grouped along parallel sort mechanism takeawayconveyors are presented for packing in such a manner that multiplecartons can be picked up and packed into boxes 704 in a single motion(as opposed to packing cartons one at a time). The packer must, however,still determine how many cartons to pack into which boxes. Withoutdeparting from the scope of the present invention, the process of movingcartons from the end of the sorting mechanism takeaway conveyor intoboxes 704 can be entirely automated, semi-automated or entirely manuallyaccomplished. Packing system software components 314 are illustrativelyconfigured to support the implemented packing functionality.

In one example of a purely manual implementation, a human operator picksup the cartons and simply places them in pre-assigned boxes. Theoperator may be guided by instructions reflected in a paper-basedlisting, for example, a paper-based listing of what products should bepacked where. In one embodiment, software component 314 is configured tosupport the generation of the paper-based listing based on defaultand/or administrator- or operator-selectable system parameters.

In one embodiment of a semi-automated implementation, the operator picksup cartons and decides which box to put them based on an electronicallysupported system that presents automated cues (e.g., visual or audiblecues). In one embodiment, a mechanism is employed to verify that humanhas properly responded to the cues. For example, the system may requirethe human to provide feedback (e.g., pushing a button, speak a commandinto a microphone, etc.) to verify compliance with a particular cue,which illustratively triggers initiation of the next cue. An alarm orsome other response is illustratively provided if feedback from theoperator is inconsistent with expectations based on the currently activecue. In one embodiment, software component 314 is configured to supportthe management of the semi-automated packing process (including thehandling of exceptions or errors) based on default and/or administrator-or operator-selectable system parameters.

In a more specific example of a semi-automated implementation, an LED isilluminated to identify cartons (e.g., the identity, SKU and/orlocation) as the next candidate for packing. The same or a different LEDmechanism also indicates the quantity to be packed. The same ordifferent LED mechanism identifies what box to pack the cartons in. Oncepacked, the LED mechanism or mechanisms are turned off in a manner thatindicates compliance with the picking instruction. This may occur in anyof a variety of different ways such as, but not limited to, depressionof a button by the operator. Alternatively, the indicator(s) may beautomatically extinguished when determined by a sensor (e.g., anelectronic eye, a laser sensor, etc.) that the current pickinginstruction is likely to have been fulfilled. In one embodiment,software component 314 is configured to support the management of thesemi-automated process (including the handling of exceptions or errors)based on default and/or administrator- or operator-selectable systemparameters.

In another example, an audibly directed system is implemented whereinaudible commands are transmitted to an operator-worn headset to notify ahuman operator of the next box to pack in, a quantity to be packed,and/or some other form of instruction. In one embodiment, the operatorspeaks into a microphone to notify the system, via speech recognition,of exceptions and/or packing verification. It should be noted thathybrid systems are also within the scope of the present invention, suchas a system wherein visual aids are utilized to provide packinglocations and audible cues are utilized to indicate the applicablequantity, exceptions, completions, and/or other packing-relatedinformation. In one embodiment, software component 314 is configured tosupport the management of the packing process (including the handling ofexceptions or errors) based on default and/or administrator- oroperator-selectable system parameters.

In one embodiment, pick-up sensors are provided at the carton pick-uppoint on the proximal end of the sorting mechanism takeaway conveyor.The sensors are illustratively configured to produce a signal indicatingwhen cartons have been picked up, and to identify which parallel row ofthe sorting takeaway conveyor the picked up cartons belong to. Put-downsensors are illustratively provided proximate boxes 704 and areconfigured to identify in which box 704 picked up cartons have beenplaced.

FIG. 9 is a flow chart diagram demonstrating steps associated with oneimplementation of pick-up and put-down sensors. In accordance with box902, pick-up sensors identify a pick-up instance. In accordance withblock 904, put-down sensors identify a putdown instance. In accordancewith block 906 a determination is made as to whether the put-down isconsistent with the pick-up (e.g., whether it was an accurate put-down).If not, in accordance with box 908, an exception or error-handlingprocess is initiated (e.g., an alarm is triggered, etc.). In accordancewith box 910, if the put-down was accurate, the process is repeatedfollowing the next sensed pick-up instance. In one embodiment, softwarecomponent 314 is configured to support the management of thepick-up/put-down process (including the handling of exceptions orerrors) based on default and/or administrator- or operator-selectablesystem parameters. In one embodiment, the described pick-up/put-downsystem is implemented in conjunction with a system, such as but notlimited to those described herein, for instructing the operator as towhich items to pick up and where to put them.

Those skilled in the art will appreciate that the implementationsprovided in the previous paragraphs are simply examples of manyalternatives within the scope of the present invention. Fully automatedalternatives, such as where machines handle automatically the process ofmoving cartons into boxes 704, are also within the scope of the presentinvention. The present invention is not limited to any one particularmeans for implementing the packing process.

In accordance with one embodiment, one or more display panels are madevisible to an operator responsible for packing boxes 704. When ashipping container (i.e., a box 704) is full, software system 304 causesthe display panel(s) to show a graphical depiction of what the fullcontainer should look like from the operator's point of view. Forexample, the brand logos on the end of the cartons collectively form animage of sorts. The operator compares the graphical representation onthe display panel to the appearance of the cartons in a full box. Inthis manner, the operator uses the display panel as a mechanism toverify that the shipping container has been properly filled. In oneembodiment, filling exceptions or errors are reported and/or correctedby interacting with software system 304 through inputs into the displaypanel or an associated input mechanism.

In one embodiment, after a container (e.g., a box 704) has been properlyfilled, a shipping label is manually or automatically applied (though itis also within the scope of the present invention to apply the shippinglabel before or during the packing process). In one embodiment, the boxcontent (e.g., by SKU, by quantity, etc.) is indicated on the label.Once labeled, the container is put on a takeaway conveyor. In oneembodiment, with reference to FIG. 8, user 802 can send out a fullypacked and labeled box 704 simply pushing the box backwards onto atakeaway conveyor located behind the boxes.

In accordance with block 210, another step in the process is the routingof the packed containers for final shipping. FIG. 10 is a schematicrepresentation of an accumulation area 1004. Full containers (e.g., thecontainers pushed back onto takeaway conveyors by user 802 in FIG. 8)are moved into the accumulation area on conveyors 1002. Two conveyors,an upper conveyor configured to move boxes 704 stacked on top and alower conveyor configured to move boxes 704 stacked on bottom, are shownin FIGS. 1 and 8. However, more or fewer takeaway conveyors can beimplemented to support a particular packing station configuration (e.g.,to support more or fewer sorting mechanisms 140).

In one embodiment, as containers approach accumulation area 1004, areader (e.g., a radio frequency reader, a barcode reader, etc.) isconfigured to identify the packages. Based on default and/oradministrator- or operator-defined parameters set within software system304, some packages are illustratively diverted into the accumulationarea 1004, while other packages may be allowed to continue past theaccumulation area to a shipping area. Shipping containers in theaccumulation area are illustratively re-circulated, read, and routed tothe shipping area when system parameters indicate that such action isappropriate.

There are a variety of interesting features associated with theembodiments of materials handling systems described herein. For example,various system components enable products to be brought to a humanoperator rather than requiring the operator to move to the products.

Further, sorting mechanism 140 is configured to sort products intospecific orders, rather than requiring operators to pick up the productsand sort them, for example based on digital lights, etc.

Further, products can be routed through multiple stamping machines whilemaintaining product identity. If one stamping machine is stamping forone state, a second stamping machine can be stamping for a differentstate. However, orders from both states can be picked in the same batch.

Further, multiple products can be handled simultaneously. For example,at the end of sorting mechanism 140, multiple cartons (e.g., sixcartons) can be picked up. Cartons can be picked up in groups of three,two, six, etc.). In one embodiment, due to the functionality of asorting mechanism 140, when the operator retrieves a group of cartons,the cartons come directly proximate to the case in which they are to belocated. This list of benefits is not exhaustive. These are justexamples of many potential benefits.

Although the subject matter has been described in language specific tostructural features and/or methodological acts, it is to be understoodthat the subject matter defined in the appended claims is notnecessarily limited to the specific features or acts described above.Rather, the specific features and acts described above are disclosed asexample forms of implementing the claims.

1. A computer-implemented method for processing tobacco-oriented goods,the method comprising: receiving a pick-up signal from a pick-up sensor,wherein the pick-up signal is indicative of the picking up of a tobaccoproduct unit that has been pre-sorted based on inclusion in anassociated order; receiving a put-down signal from a put-down sensor,which the put-down signal is indicative of the fact that the tobaccoproduct unit has been put down; determining, based on a systemparameter, whether the pick-up signal is properly associated with theput-down signal.
 2. The method of claim 1, wherein receiving a pick upsignal further comprises receiving a pick up signal indicative of thepicking up of a tobacco product unit that has been pre-sorted based onan identifier attached to the tobacco product unit.
 3. The method ofclaim 1, wherein receiving a pick up signal further comprises receivinga pick up signal indicative of the picking up of a tobacco product unitthat has been pre-sorted based on a barcode identifier attached to thetobacco product unit.
 4. The method of claim 1, wherein receiving apick-up signal further comprises receiving a pick-up signal following apicking up of multiple tobacco product units including said tobaccoproduct unit.
 5. The method of claim 1, wherein receiving a pick-upsignal further comprises receiving a pick-up signal following a pickingup six tobacco product units including said tobacco product unit.
 6. Themethod of claim 1, wherein receiving a pick-up signal from a pick-upsensor comprises receiving a pick-up signal from a photo-eye sensor. 7.The method of claim 1, wherein receiving a pick-up signal from a pick-upsensor comprises receiving a pick-up signal from a sensor positionedproximate to a sorting mechanism configured to sort a plurality oftobacco product units based on at least one order parameter, saidtobacco product unit being one of the plurality of tobacco productunits.
 8. The method of claim 1, wherein receiving a put-down signalcomprises receiving a put-down signal that is configured to sense whenthe tobacco product unit has been placed into a shipping container. 9.The method of claim 1, wherein receiving a put-down signal comprisesreceiving a put-down signal that is configured to sense into which of aplurality of shipping containers the tobacco product unit has beenplaced.
 10. The method of claim 1, wherein receiving a put-down signalcomprises receiving a put-down signal that is configured to identifywhich of a plurality of locations is the location at which the tobaccoproduct unit has been placed.
 11. A materials handling system forprocessing tobacco-oriented goods, the system comprising: a sortingmechanism configured to physically distribute tobacco product units intoa plurality of groups based on an order-oriented characteristic; apick-up sensor configured to produce a pick-up signal when a unit hasbeen removed from one of the plurality of groups for packaging purposes;and a put-down sensor configured to produce a put-down sensor indicativeof a location where the unit removed for packaging purposes has been putdown.
 12. The system of claim 11, further comprising a processingmechanism configured to determine, based on a system parameter, whetherthe pick-up signal is properly associated with the put-down signal. 13.The system of claim 11, further comprising a monitoring mechanismconfigured to trigger an exception routine if the pick-up signal is notproperly associated with the put-down signal.
 14. The system of claim11, wherein the sorting mechanism is configured to physically distributetobacco product units into a plurality of groups, at least two groupsbeing divided based on a characteristic that allows units from the sameorder to be in different groups.
 15. The system of claim 11, furthercomprising an information gathering system for associating an identitywith each tobacco product unit prior to being made available to thesorting mechanism.
 16. The system of claim 11, further comprising aninformation gathering system for collecting barcode informationassociated with each tobacco product unit prior to being made availableto the sorting mechanism.
 17. A computer-implemented method forprocessing tobacco-oriented goods, the method comprising: triggering anelectronic transmission of a pick-up signal by picking up a plurality oftobacco product units that have been pre-sorted based on anorder-oriented characteristic; triggering an electronic transmission ofa put-down signal by putting down the tobacco product units; andreceiving an indication that the pick-up signal has been compared to theput-down signal and a determination has been made that a locationassociated with the put-down signal is not properly correlated to thepick-signal.
 18. The method of claim 17, wherein triggering a pick-upsignal comprises triggering a line of sight sensor positioned proximateto a sorting mechanism.
 19. The method of claim 17, wherein triggering aline of sight sensor positioned proximate to a shipping container. 20.The method of claim 17, further comprising comparing a collection oftobacco product units in the location with a visual display to determinewhether the collection of tobacco products is properly grouped.